Building modular and panel system and method of construction thereof

ABSTRACT

A building modular and panel system for construction using prefabricated modular panels. The system includes top and bottom plates connected to metal studs. A high rib metal lath with moisture barrier backing can be secured to and covers the metal studs. A light weight gas injected concrete/plaster seizer mix is sprayed over the metal lath to create the structural panel. The structured panel is preferably bolted to the slab. To provide further support, especially in a commercial setting, one or more lateral wall channel bracing can be attached to the metal studs.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to building construction andbuilding materials and more particularly to a novel modular and panelsystem for a building and novel method of construction of the building.

2. Description of the Prior Art

The three basic components for residential construction shells generallyare the foundation, the frame or skeleton and the skin. The foundationincludes contiguous structural elements typically set on contiguousconcrete footing poured into excavations in the ground beneath. Theframe includes the floor, the exterior walls, and the roofing joists.The skin has both exterior and interior applications and includeswhatever materials or layers that are applied or connected to the frame.The skin also includes insulation, drywall, roofing systems, etc. Thehouse or other building (collectively referred to as “building”) is puttogether piece by piece outdoors where all of the raw materials for thebuilding and the building processes are subject to all of the elementsof nature.

Successful construction, in any climate, is always dependent upon theavailability of weather suitable to the type of construction. Thus, arelevant factor is the suitability of the construction materials andmethods to the available weather. Conventional construction is limitedto those types of materials which pass the stringent fire safety codes.Most often, this is usually some form of masonry. While the materials ofwhich blocks and bricks are comprised are not specifically susceptibleto the exigencies of cold and heat extremes, or even to the particularpresence or absence of moisture, the methods for bringing the blocks andbricks together are.

Conventional construction typically has at least five distinct parts orphases to it, each of which is separate and must be concluded before thenext can be started. They are: (1) site prep, which includes theclearing of the land and the excavation of the slab and/or footers; (2)foundation, which is the pouring of the concrete for footers and thepouring of any basement or slab flooring; (3) framing, usually of woodstuds and joists (often referred to as “stick built”) covered withplywood chip board, or some similar material; (4) sheathing, which, isthe block or masonry outer “skin” (which may or may not include a“moisture barrier” and the roofing; and (5) finishing, which is all ofthe interior trades. Four of these five phases are conducted exclusivelyoutdoors, where temperatures and conditions limit the circumstancesunder which they can be affected. While these items are worked out, allother trades are at a standstill until the building (house) is declaredto be “in the dry”. In view of these delays, there are often longperiods of weeks and months each year when traditional builders are idleand construction is halted or intermittent at best in the northernclimate.

Home ownership slips further and further from the grasp of a growingproportion in the United States and elsewhere. The conventional buildingmaterials and methods of construction described above do not lendthemselves to a workable solution for the needs of affordable housing.It is to the effective resolution of these and other problems associatedwith conventional building materials and methods of construction thatthe present invention is directed.

SUMMARY OF THE INVENTION

The present invention generally provides a building modular and panelsystem for construction using prefabricated modular panels and methodfor construction the building primarily offsite, such as, but notlimited to, indoors at a factory. The system includes a frame having topand bottom plates and a plurality of metal studs, preferably constructedfrom galvanized steel. The top and bottom plates are connected to themetal studs. The studs can be provided with one or more holes orapertures for running electrical wiring, cable, computer wiring,plumbing, etc., as well as for bridging purposes.

A high rib metal lath with or without a moisture barrier backing can besecured to and covers the metal studs. A light weight gas injectedconcrete/plaster seizer mix can be sprayed over the metal lath to createthe structural panel. The structured panel is preferably bolted to theslab, such as, but not limited to, by the use of anchor bolts. Toprovide further support, especially in a commercial setting, one or morelateral wall channel bracing can be attached to the metal studs.

In one non-limiting embodiment, the concrete mixture sprayed on to themetal lath can consist of an amount of Portland Type 1 cement, an amountof sand (40-60 screen size), and a plaster seizer, with or without acement accelerator. In one embodiment, three coats are spray applied tothe lath preferably by using a three-coat machine. The exterior finishcan be approximately in thickness, though such is not consideredlimiting.

Any required electrical and rough plumbing items can then be installed,as well as any other items such as, but not limited to, cables, computerwiring, etc. At this point the insulation material can also be installedwithin the interior area. Grommets can also be installed in the studapertures to isolate or prevent the installed electrical wiring orplumbing from directly contacting the metal studs. The internal area ofthe final panel can be preferably filled with insulation material.Though not limiting, in the preferred embodiment, R-19 or R-20 ratedinsulation can be used for the insulation. The insulation can beprovided with a Kraft paper backing to provide a moisture barrier.Additionally or alternatively, a paper backing can also be provided onhigh rib lath.

The interior side of the panel can be completed by the attachment ofdrywall or gypsum board to the metal studs. Alternatively, a lathassembly can also be provided on this (interior) side of the panel if sodesired.

Using the materials and methods described herein, the present inventionprovides a more cost effective way of producing pre-site built modularand panel systems, which at the same time produces a faster built,stronger and environmentally safer commercial and/or residentialbuilding.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective partial cutaway view of a first embodiment for amanufactured panel in accordance with the present invention;

FIG. 2 is a perspective partial cutaway view of a second embodiment fora manufactured panel in accordance with the present invention;

FIG. 3 is a perspective view of a frame assembly for the manufacturedpanel of FIG. 1;

FIG. 4 is a perspective view of the metal lath assembly for themanufactured panel of FIG. 1 shown partially covering the frame assemblyon the exterior (outside) side of the frame assembly of FIG. 3;

FIG. 5 is a perspective view of an exterior finish partially applied tothe metal lath disposed on the exterior (outside) side of the intendedstructure, with the metal lath now shown fully covering the metal studsof the frame assembly of FIG. 3;

FIG. 6 is a perspective view illustrating certain electrical andplumbing components installed within the manufactured panel; and

FIG. 7 is a perspective view illustrating drywall being secured to theframe assembly on interior (inside) side of the frame assembly of FIG.3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As seen in FIG. 1 a first embodiment for a manufactured panel isdisclosed and generally designated as panel 20. Panel 20 generallycomprises a frame assembly 30, a metal lath 70, an exterior finish 90and an interior finish 96. Panel 20 can be preferably attached to aconcrete slab 25, which has been previously been formed throughconventional practices. FIG. 2 illustrates a second embodiment for themanufactured panel which is highly similar to the first embodiment, withthe addition of lateral wall channel bracing provided, which can bepreferably equally spaced up the wall and attached to the metal studs ofthe frame assembly 30. In one non-limiting embodiment, lateral bracingcan be spaced out in ⅓^(rd) lengths of the wall height, though such isnot considered limiting. Though also not considered limiting, thelateral bracing can be preferably provided for commercial buildings anda panel 20 without bracing can be used for residential buildings. Thebelow description for the invention is considered applicable to both thefirst embodiment (FIG. 1) and second embodiments (FIG. 2) of theinvention.

As best seen in FIG. 3, frame assembly 30 comprises a top track 34, abottom track 46 and a plurality of wall studs 60. In one embodiment, toptrack 34 and bottom track 46 can both be a “U” shaped channel runners,having a web 36 and 48, respectively of approximately 6″ and leg (38 and50, respectively) heights of approximately 1¼″. Tracks 34 and 36 can beapproximately 10′ in length. These disclosed dimensions for top track 34and bottom track 46, as well as all other dimensions discussed herein,are given by way of example and are not considered limiting.Accordingly, other dimensions for the various components of panel 20 canbe used and are considered with the scope of the invention. Tracks 34and 46 can be preferably constructed from 18 gauge metal though othergauges can be used and are considered within the scope of the invention.

Wall studs 60 can also be preferably constructed from 18 gauge metalthough again other gauges can be used and are considered within thescope of the invention. Studs 60 can be “C” shaped members which withtop track 34 and bottom track 46 form frame assembly 30 for the axialload bearing walls. Studs 60 can be provided with one or more holes orapertures 62 for electrical wiring, cable, computer wiring, plumbing,etc., as well as for bridging purposes. In one non-limiting embodimentapertures 62 can be approximately 24″ on center and have a knockout sizeof approximately 1½×approximately 4″. However, other dimensions can beused and are considered within the scope of the invention. The knockoutcan be punched at approximately 12″ from the leading edge withadditional knockout at approximately 24″ on center. Again thesedimensions are given by way of example and are not considered limiting.As the knockouts (apertures 62) are used for plumbing and electricalitems it is preferred that they are substantially aligned from studs 60.

Studs 60 are attached to top track 34 and bottom track 46 throughconventional such as by fasteners 64. In a preferred, thoughnon-limiting embodiment, a powder actuated fastener technique can beused to attached studs 60 to tracks 34 and 46. In a preferredembodiment, two fasteners 64 on each side (interior and exterior) ofstud 60 for a total of four fasteners 64 attach stud 60 to top track 34.Similarly, two fasteners 64 on each side of stud 60 for a total of fourfasteners 64 attached stud 60 to bottom track 46. Thus, in the preferredembodiment, a total of eight fasteners 64 can be used for attaching eachstud 60 to top track 34 and bottom track 46. However, it should berecognized that the present invention is not limited to any particularnumber of fasteners or that the same number of fasteners have to beprovided for attaching stud 60 to the top track 34 as for attaching stud60 to bottom track 46. Accordingly, other number of fasteners can beused and are also considered within the scope of the invention. In onenon-limiting, embodiment, fasteners 64 can be #10 self tapping Philiphead low profile or framing screws. However, other screws, bolts,rivets, nails, etc. can be used for fasteners 64 can be used and arealso considered within the scope of the invention. Though not preferred,other mechanisms for securing studs 60 to tracks 34 and 46 can also beused and are considered within the scope of the invention, such as, butnot limited to, welding, gluing, etc. Though also not consideredlimiting, two screws at the top and two screws at the bottom for eachside of each stud 60 can be used for attaching studs 60 to tracks 34 and46.

Studs 60, top track 34 and bottom track 46 together comprise frame orwall assembly 30. Frame assembly 30 can be preferably fastened toconcrete slab 25 preferably by using a power fastener. In onenon-limiting embodiment fasteners 48 can be anchor bolts, preferablyhaving a hex head formed with an integral washer. The anchors can bepreferably designed to be used with a matched tolerance anchor boltdrill bit having the same tolerance and dimensions as the anchor boltfor optimum fastening results.

FIG. 4 illustrates metal lath assembly 70 which can preferably comprisea ⅜″ high rib lath 72 having herringbone mesh pattern with ⅜″ V-shapedribs running the length of the sheet at 4½″ intervals and inverted 3/16″intermediate ribs. The preferred dimensions are not considered limitingand other dimensions can be used for metal lath 72 and are consideredwith the scope of the invention. As seen in FIG. 4 high rib lath 72 isplaced against framing assembly 30 and attached to framing assembly 30through fasteners 74, such as but not limited to #10×1″ self tappingPhilip head screws at maximum 8″ on center. In one non-limitingembodiment fasteners 74 can be provided at one or more points of eachstud 60. Lath 72 can be provided with a kraft paper backing to serve asa moisture barrier. Lath 72 with its small opening patters receives therelatively lightweight concrete which causes the concrete and the lath72 to join and become one with the studs 60 to create a structuralpanel.

FIG. 5 illustrates the final step for the exterior side of panel 20 inwhich a one or more coat concrete finish is applied to high rib lath 72.In one embodiment, three coats are spray applied to lath 72 using athree-coat machine. Exterior finish 90 can be approximately 2″ inthickness, though such is not considered limiting and other thicknessescan be used and are considered within the scope of the invention. In thepreferred three coat finish 90, the first coat can serve as a scratchcoat, the second coat can service as a brown coat and the third coat canserve as a finish coat. The concrete mixture can consist of a cement,aggregate and admixture. In one non-limiting embodiment, the cement canbe a Portland type cement, the aggregate can be a sand and the admixturecan be a plaster seizer mix with or without an accelerator or cementaccelerator. The Portland cement can be of a Type I kind and the maximumsize for the sand can be about 40—about 60 screen size. One non-limitingratio for the ingredients or components of the concrete mixture given inproperties per cubic foot can be (i) 8 bags of Portland Type I cement,(ii) 20 cubic foot of sand; (iii) 32 ounces of plaster seizer mix and(iv) 32 ounces of accelerator. The plaster seizer mix can be a compositeof lightweight concrete, made lighter than normal concrete byintroducing gas bubbles into the plastic cement mix to create a novelmaterial with a cellular structure. The gas or air bubbles can beproduced by a chemical reaction which takes place within the freshmortar/cement mass. The structural concrete produced by the presentinvention can be effective in controlling both sound absorption andtransmission. The structural concrete of the present invention used inthe modular and panel systems of the present invention is lighter inweight, different in composition, more controllable in production, moreversatile in applications, spreads easier, has more yield, betterthermal, acoustical and frost resistant properties, and costs less thanstandard concrete.

FIG. 6 illustrates the step for installing the required electrical andrough plumbing items, as well as any other items such as, but notlimited to, cables, computer wiring, etc. FIG. 6 also illustrates theinstalling of the insulation material within the interior area that isdefined inside panel 20. Grommets 66 can be installed in apertures 62 ofstuds 60 to isolate or prevent the installed electrical wiring orplumbing from contacting the metal studs 60. The grommet 66 size can be1½″ or otherwise correspond to the size of apertures 62. Grommets 66 cansnap into or otherwise be attached within apertures 62 in studs 60 andopenings 38 and 50. Where needed, one or more openings 38 can beprovided in top truck for feeding or running wiring, plumbing, etc.through. One or more openings 50 can be provided in bottom track 46 forsimilar purposes. Grommets 66 can also be provided for openings 38 oftop track 34 and openings 50 of bottom track 46. Any remaining void inapertures 62 after installing the above-described electrical, plumbing,etc. can be filled with a foam or other non-conductive material.

As also seen in FIG. 6, the internal area of panel 20 can be filed withinsulation material. Though not limiting, in the preferred embodiment,R-19 or R-20 rated insulation 68 can be used for the insulation. Howeverother rated insulation can also be used and are considered within thescope of the invention. The insulation can come in various forms,including, but not limited to, batts, rolls, loose-fill, and rigid foamboards and all are considered within the scope of the invention.Insulation 68 can be provided with a kraft paper backing to provide amoisture barrier. As mentioned above, the paper backing can also beprovided on high rib lath 72 in addition or as an alternative toinsulation 68.

As seen in FIG. 7, the final step for he interior side of the panel 20is the attachment of drywall or gypsum board 96 (collectively referredto as “gypsum board”) to studs 60. Alternatively, a lath assembly canalso be provided on this (interior) side of panel 20. In a non-limitingpreferred embodiment the gypsum board can be ⅝″ in thickness, thoughother dimensions can be used and are considered within the scope of theinvention. Standard fasteners 98, such as but not limited to, drywallscrews or self-tapping drywall screws can be used for attaching gypsumboard 96 to studs 60. In one non-limiting embodiment, #6×1¼″ long withcountersunk Philip head screws preferably at a maximum of 8″ on centerand minimum of 6″ on center. However, other dimensions for the screwsand other distances for their location can be used and are consideredwithin the scope of the invention.

The joints of the present invention building system can be “moment”connection, capable of resisting rotation. Steel and galvanized lightweight cement skin preferably forms “composite” construction workingtogether which can be performed in a factory setting. All adjoiningwalls can be bolted and sealed together using the concrete mixture ofthe present invention.

Preferably the entire concrete floor or slab is poured and complete sothat the modular or panel system of the present invention can beattached thereto as discussed above. However, the present invention canalso be used to create a floor system as well. In this embodiment, thelightweight concrete discussed above can be installed in a thickness,such as, but not limited to, about 2″ over a floor joist or floor trusswith the same high rib metal mesh lath. The resulting floor can besignificantly stronger than floor systems created using industrystandards.

Each member of the present invention frame resists force placed on anyother members and spreads the resistance over all members. As allmembers add together they can be relatively lighter. Thus, the presentinvention acts as a structural system. With the present inventionbuilding system, rafters and trusses can be become part of the wallsystem. Slab anchors (anchor imbedded in slab) can also be imbedded inthe wall. Each wall panel can have a reinforced relatively light weightcement skin to resist sheer. As there are preferably no overturning,truss or rafters can be on 2-foot centers. Additionally, lintels may notbe required. The present invention can provide for a screwed roofstructure covered with roof shingle to resist or reduce deformation. Thepreferred cement skin of the wall can form a “stress-skin-panel”, whichcan provide an efficient structural form. From an appearance standpoint,an attractive cement surface can be provided on the outside wall. Thecement can be light weight and waterproof and thus little or nomaintenance is needed.

As to the foundations and/or slabs, the present invention provides forconcrete strip footing or slabs. The steel panels can be set right onfooting or slab and can be at 33,000 psi. The modular panel systems ofthe present invention can be bolted in the floor slab. The walls can beanchored by steel bolts, such as, but not limited to, 6″ steel bolts at2′ o/c. The present invention can provide for a reinforced 3,000 psi“earth tempered” floor slab which can conduct earth crust temperatureinto living areas (i.e. crust typically varies from about 60° F. toabout 65° F. As the concrete slab—3,000 psi, any flooring may beapplied.

The exterior walls produced through the present invention in a preferredembodiment provide for a 30,000 psi minimum galvanized screwed steelframe. The walls can include metal studs, preferably steel, such as, butnot limited to, 6″ steel studs at 16″ o/c. The walls can also include agalvanized structural metal lath sheathing as reinforcing to lightweight cement vertical mini-slab monolithic shell (4,000 psi). Theexterior walls can be fireproof and resistant to mold, mildew, fungus,bacteria, termites, ants, vermin, etc. The exterior walls can also beinsulated to R19 or R20 and the preferred galvanized steel will not rustor burn. The system can be designed to retain energy by using aninsulated heat reflecting barrier and high insulation values in wallsand roofs.

The exterior facing for the wall can provide a light weight, textured,seamless cement-based weathercoat which “breathes” to allow water vaportransmission to avoid damp wall cavities. The cement coat can beimpervious to ultra-violet sunlight exposure. The cement coat ispreferably unremovable manually, fireproof, seamless, no air leaks,burglar resistant and 4,000 psi. As referenced above, the structure canbe preferably galvanized screwed steel frame encased in reinforced lightweight cement and structural wall. The facing will not rust ordeteriorate and does not provide for a breeding ground for mold, mildew,fungus, bacteria, termites, ants, vermin, etc. The exterior surfaces canbe tinted and weatherproofed with a finish coat cement mixture to createthe color and texture required. As the surface can be impervious tomoisture penetration, any shape or ornamentation can be relativelyinexpensively formed.

The joists, rafters and studs can be preferably pre-punched for serviceruns. This permits easier installation at the factory of electrical,plumbing, HVAC, etc. Grommets, such as but not limited to, rubber orplastic grommets, can be inserted into punch-outs to avoid contact itemsinserted through the punch-outs (e.g. pipes, wires, etc.) with the frame(metal studs, galvanized steel studs, etc.). The roof frame canpreferably include 33,000 psi galvanized steel rafters screwed togetherto form a single structural unit with the walls. These mini-slab roofscan create a single unified structural skin, which preferably preventsor reduces pull-outs or blow offs. Use of the present invention providesfor a roof having increased stability and rigidity in view of the framemetal tiles being compatible with the steel frame. Enameled galvanizedmetal screws preferably with rubber washers can be used to joincompatible materials.

The present invention provides for a monolithic seamless structuralshell made of compatible materials which allows for the cement-steelbond to become a single structural piece. The average material strengthcan be 25,000 psi and higher, which is significantly stronger thanconventional materials. The structural is also durable in view of littleor minimal deterioration of the cement over an extended period of time(i.e. approximately 100 years, etc.) and the preferred use of galvanizedsteel to increase lifespan of the steel and resulting unified structure.The structure preferably is fireproof and non-combustible. The exteriorappearance can be of a stucco type and can include a wide variety oftints and textures.

Significant environmental advantages are also achieved through thepresent invention building system as the steel industry usedapproximately 1/100^(th) of land area as compared for that needed fortimbering; the system used approximately 1/10^(th) of an amount ofcement as conventional masonry or concrete, the construction steelindustry typically recycles 100 percent, as the building ispre-fabricated there is minimal if any trash at the site.

The walls and roofs of the present invention building system can beapproximately two inches thick yet they provide significant insulationand effect energy savings. Insulation batts can be installed, sprayedand/or treated. In one non-limiting embodiment, the insulation can beapproximately 6″ fiberglass insulation installed into the walls and/orattics.

Any cabinetry, shelves and/or accessories to be secured to the wall canbe provided with a blocking having a steel track for securing toassociated studs, such as, but not limited to, studs associated with thebathrooms and/or kitchens.

The steel and lightweight cement components of the present inventionform a strong combination. The preferred steel framework integrated witha continuous reinforced cement exterior surface, provides the strengthto resist storms, floods, earthquakes and other natural disasters. Thereinforced cement can form a right shell encasing the steel frame. Thecement coat can bond to the frame creating a unified steel andlightweight structure. This composite stress skin structure is verystrong for its weight, providing durability and disaster resistanceusing a fraction of the material traditionally required.

Once built, the pre-engineered construction system can be easilytransported to the building site. The modular or panel systems can bedelivered to the site finished and installed on the foundation or slab.All plumbing, electrical, air condition and heating, cabinet and counterwork can be done at the factor except for utility connections. Thesystem can include, but is not limited to, panelized exterior walls,roofs, ceilings, intermediate floors, partitions, and stairs. The panelsare relatively lightweight and can be easily placed with a minimum ofon-site equipment. As no cutting or framing is required, the presentinvention provides a relatively fast and affordable constructionbuilding system.

When constructing a building using the present invention buildingsystem, site prep becomes less critical as compared to conventionalbuilding techniques since the combined weight of the completed buildingis about 1/10^(th) that of a conventional building. With the presentinvention the footers can be poured at about the same time as the siteis being prepped, and thus, reducing time frames significantly. Thepouring of the concrete slab, whether for a slab foundation or as partof the basement floor, can be left until after a substantial part (ifnot all) of the framing has been finished. Time requirements for framingare thus substantially reduce, except possibly for erecting the framesand attaching them from one to another. Furthermore, the framing can beperformed indoors under controlled climate conditions. Additionally,with the present invention, framing and sheathing can take placevirtually simultaneously and the roofing can begin as soon as the upperportion of the building has been erected into place. This process isrelatively rapid as compared to conventional building techniques, suchthat the weather envelope does not have to lengthy in order to get thebuilding “in the dry”. With the framed “skeleton” of the building up,the entire structure can be plumbed and electrical wiring can beinstalled. When finished with all doors and windows in place, thestructure can be inspected under ideal conditions at the factory. Coldconditions do not become a major issue as approximately 85% of thestructure can be built indoors at the factory.

The present invention can provide at least some, if not all of the belowobjects and/or advantages:

(1) overcomes obstacles that have created and continue to sustainaffordable housing and building shortages;

(2) provides a finished, pre-engineered product;

(3) results in finished products which can meet and surpass the highestbuilding code standards;

(4) a completed building using the present invention, whetherresidential or commercial, can be provided with superior fireresistance;

(5) completed structure and structural components can be non combustibleand non friable;

(6) completed structure and structural components can have zero smokecontribution and zero out gassing preferably without any other coatingor treatment;

(7) provide superior lightning resistance where the entire frame of thebuilding can be grounded with nothing flammable for the lightning toignite;

(8) the finished product can have a combined strength rating ofapproximately 30,000 P.S.I.;

(9) the strength of the present invention building system can allow forunusually long spans without trusses or load-bearing walls, which canafford more open and innovative living designs while mitigating costs;

(10) the completed pre-engineered structures can use substantially lessmaterials than are consumed in conventional construction (i.e.approximately ⅛^(th) of cement and approximately ½^(th) of steel, etc.);

(11) the completed structures can be relatively light weight (i.e.approximately ten to approximately 20 percent of the weight of aconventionally constructed building), and preferably employs norelatively large/heavy components, which in the event of a earthquake orother natural disaster could crash down on an occupant of the building;

(12) the exterior shell can be designed so as not to collapse underextreme force or blow out;

(13) the frame can be designed to give way on impact without pullingdown the exterior shell;

(14) the present invention building system can consume little or nolumber in its construction, thus sparing approximately 150 treestypically used to build an average-sized house;

(15) the structure can be constructed without hydrocarbons or resins andcan use materials with a proven history of longevity;

(16) the system can use materials that are readily, abundantly andeconomically available to eliminate or reduce possible market shortages;

(17) materials used in the building system can be compatible with oneanother to reduce or eliminate any chance for reactions which couldcause deterioration;

(18) can reduce or eliminate rusting of metal;

(19) materials used can have relatively low and virtually equalcoefficients of thermal expansion and contraction such that shrinkage isminimized, even under extreme temperature variances, and the integrityof the material is not compromised;

(20) the building system becomes a unitized structure, preferably ableto meet and resist building, wind, precipitation and movement leads as aunified whole rather than as separate components fastened and attachedtogether;

(21) a pre-engineered structure at one with its foundational system,such as by being attached, strapped, bolted or fastened as opposed tomerely stuck to;

(22) a building system incorporating a roof deck and roof systemattached to the foundation and exterior walls such that no known naturalwind force up to approximately 180 mph can separate the roof from therest of the structure;

(23) completed structure preferably strong enough and adaptable enoughthat choices for roofing are based on budget and aesthetics;

(24) the strength of the finished building built to withstand sustainedwind loads in excess of 180 mph;

(25) a building system designed so that repairs can be effected quicklyand affordably;

(26) vertical and horizontal planes of the completed structure are plumband square;

(27) clearances and tolerances for the installation of windows and doorscan be kept relatively very low and not dependent upon the use ofcaulks, fillers and weather stripping to achieve proper fit;

(28) windows can be constructed using highly efficient high impact glassor storm shuttered windows;

(29) window frames and doors can be of durable, waterproof,non-combustible and/or non-decomposing material;

(30) the exterior weatherproof skin can be impervious to water indroplet form, repelling and resisting it, and preferably incapable ofwicking or absorbing water into the interior of the system;

(31) the surface skin can preferably be crack resistant, color fast,resistant, shrink resistant and structurally resilient;

(32) the skin can be preferably applied either by hand or by spray;

(33) the materials used for the skin can be preferably tailored forvarious climates, regardless of temperatures and humidities;

(34) the system can be designed such that its strength can preclude orreduce the necessity of floodgates in areas susceptible to flashflooding;

(35) the system can be water and rust resistant such that in the eventof flooding there is preferably no permanent damage to the structuralcomponents of the building;

(36) the system can be closed to climate intrusion, including, but notlimited to, wind infiltration, without the use of moisture barriers andwithout trapping fumes, solvents, hydrocarbons, vapors and/or gasesenvironmentally hazardous to the occupants;

(37) the wall system does not support the growth of mold, mildew,bacteria, or fungus and preferably can “breathe” to allow moisture vaporto be expelled while withstanding water penetration;

(38) the system does not attract, feed or sustain termites and burrowinginsects, and the chosen materials for the system can be thick and strongenough that none burrow in;

(39) the system does not attract, feed or sustain vermin or roaches andthe chosen materials for the system can be thick and strong enough thatnone burrow in;

(40) the entire building system is relatively safe and offer increaseprotection and safety from natural disasters;

(41) the finished product can be energy efficient, well insulated bothbelow and above grade and preferably designed to take advantage ofgeothermal constants;

(42) the system can have installed a heat reflective thermal breakthroughout the exterior surface of the structure;

(43) the finished structure can be relatively economical to build andown, preferably coming in will within affordable housing and buildinginitiative guidelines;

(44) the pre-engineered system and its resultant structures can beeasily and adaptable to virtually any architectural style;

(45) the system can easily lend itself to custom and upscale designs aswell as production runs of affordable housing and construction;

(46) the finished structure has an attractive appearance making itdifficult to single out as “affordable housing”;

(47) the design of the house can appear open, airy and spacious and canboast high ceilings where practical and make good use of availablesunlight;

(48) the building system can be able to economically adapt to difficultsite situations incorporating basements where possible or utilizingcrawl spaces or slabs where necessary;

(49) the building system can be able to accommodate flexible designs forsingle or multistory units and can be buildable as single ormulti-family construction;

(50) the building system is capable of providing rapid construction,such as, but not limited to, being able to be erected and ready foroccupancy in approximately three weeks regardless of weather conditions;

(51) the construction of the building leaves relatively little or nowaste at the construction site;

(52) the construction of the building can be non-polluting at the jobsite;

(53) job site construction can be relatively low noise;

(54) building construction can be achieved with simple tools, preferablywithout the use of cranes or other heavy machinery;

(55) wall systems can be designed to receive plumbing and electricalinstallations without drilling or punching, thus eliminatingapproximately sixty percent of the time such trades typically spend onsite;

(56) the building system does not require new, difficult or speciallyskilled labor which would make the building more expensive to constructand/or leave the building project vulnerable to worker shortages and/orlabor slowdowns;

(57) the factory production nor the on-site construction does notrepresent any unusual hazards or unsafe work conditions which reasonablesafety awareness and care should avoid; and

(58) raw materials can be non-toxic minerals, free fromurea-formaldehyde and allergens.

It should be noted that all figures, dimensions, temperatures, amountsare considered to be in approximates and not necessarily limited to theexact number provided. The present invention provides a panelized cementmodular pre-engineered structural system and more particularly a steeland lightweight cement pre-engineered structure. Any force applied tothe structure is resisted by the entire structural skin, reducing unitstress throughout the frame.

The amount of cement in a building constructed by the present inventionbuilding system can be approximately 1/10^(th) to approximately ⅕^(th)of that used by traditional building methods and about ½ of the steeltraditionally needed. The building can be built with no wood, nohydrocarbons, and no resins, and can be built with all-mineral contentmaterials that are non-toxic. The walls, roofs and floors of the presentinvention building do not support fungus, bacteria, mold or mildew andwill not deteriorate, rot, rust, attract termites or vermin, blow downin storms, float away in rising waters, or become a maintenance problemfor the occupants. Additionally, the building site for the presentinvention building has little or no waste left for pickup as nothingneeds to be actually fabricated at the building site. Furthermore, bypreferably producing the modular panel systems, interior and exteriorwalls, retaining and foundational walls, columns, girders, trusses,stair cases, roofs and intermediate floors at the factory and not at thebuilding site, frugal or controlled use of materials can be exercised tohelp further reduce waste and lessen strain on environmental resources.The pre-fabricated panels are of light enough weight to be erected onsite without the use of large, energy consuming, and pollutingequipment.

Where a typical wall “R” values are 12, the present invention canprovide for “R” values of 20. In conjunction with the floor or basementfloor concrete slab, the present invention building can pick up and holdthe constant temperature of the ground below the frost line, creating athermal stabilizer which can lower the amount of heating or coolingnecessary to achieve comfort in the house.

The present invention building can withstand extreme weather conditionswhich routinely destroy conventional buildings. The present inventionlight-gauge galvanized steel framework can be comprised of modular andpanel structures created from preferably about 30,000 psi rust resistantgalvanized steel imbedded in concrete floor slabs at each level and thenpreferably coated with a super-reinforced light weight cement structuralskin (about 4,000 psi). Though lighter in weight then conventionalconstruction types, this unified and cohesive pre-engineered structurecan be many times stronger than its conventional counterparts, making itrelatively highly resistant to fires, floods, hurricanes, tornadoes,mold, mildew, bacteria, fungus, termites, vermin infestation, etc.

While the invention has been described and disclosed in certain termsand has disclosed certain embodiments or modifications, person skilledin the art who have acquainted themselves with the invention, willappreciate that it is not necessarily limited by such terms, nor to thespecific embodiments and modifications disclosed herein. Thus, a widevariety of alternatives, suggested by the teachings herein, can bepracticed without departing from the spirit of the invention, and rightsto such alternatives are particularly reserved and considered within thescope of the invention.

1. A structural panel for a building comprising: a frame assemblycomprising a bottom plate, a top plate and a plurality of studs, each ofsaid plurality of studs having a bottom end and a top end, wherein thebottom end of the each stud is secured to the bottom plate and the topend of each stud is secured to the top plate, the frame assembly havingan exterior side and an interior side; a high rib mesh lath secured tothe exterior side of the frame assembly; a concrete mixture applied tothe mesh lath to form an a structural exterior wall; and an interiorwall member secured to the interior side of the frame assembly.
 2. Thestructural panel of claim 1 wherein the interior wall member is selectedfrom a group consisting of sheetrock, drywall and gypsum board.
 3. Thestructural panel of claim 1 wherein each of said plurality of studs isconstructed from galvanized metal steel.
 4. The structural panel ofclaim 1 wherein said high rib mesh lath having a plurality of smallopenings for receiving the applied concrete mixture.
 5. The structuralpanel of claim 1 wherein said concrete mixture comprises: an amount ofPortland cement, sand and a plaster seizer.
 6. The structural panel ofclaim 5 wherein said concrete mixture further comprises a cementaccelerator.
 7. The structural panel of claim 1 wherein said frameassembly having an interior areas defined between said interior wallmember, said high rib mesh lath and adjacent studs which issubstantially filled with insulation having a rating of at least R19. 8.The structural panel of claim 7 wherein each of said insulation isprovided in batt form.
 9. The structural panel of claim 1 wherein saidbottom plate is secured to a concrete slab of the building by anchorbolts.
 10. The structural panel of claim 1 wherein said lath constructedfrom metal.
 11. The structural pane of claim 1 wherein at least one ofsaid plurality of studs having an aperture.
 11. A structural wall for abuilding, comprising: a frame assembly having a top track, a bottomtrack and a plurality of metal wall studs secured at a top end to thetop track and at a bottom end to the bottom track, each of said metalwall studs having a plurality of spaced apart apertures, said frameassembly having an exterior side and an interior side; a high rib metallath secured to said metal wall studs on an exterior side of said frameassembly; a concrete mixture applied over and covering the metal highrib lath; and an interior member secured to the metal studs on theinterior side of said frame assembly and selected from the followinggroup: sheet rock, gypsum board or drywall.
 12. The structural wall ofclaim 1 wherein said bottom track of said frame assembly is secured toconcrete slab of a building by a plurality of anchor bolts.
 13. Thestructural wall of claim 11 wherein said metal high rib lath having aherringbone meshed pattern and substantially V-shaped ribs runningapproximately the length of said rib lath.
 14. The structural wall ofclaim 11 wherein said frame assembly defining an internal area betweeneach adjacent pair of metal studs, said top track and said bottom track;wherein the structural wall further comprising a piece of R-19 or higherrated insulation inserted within each internal area of said frameassembly.
 15. The structural wall of claim 14 wherein each piece ofinsulation having a moisture barrier backing paper.
 16. The structuralwall of claim 11 further comprising a moisture barrier backing papersecured to the metal high rib lath.
 17. The structural wall of claim 14further comprising wiring and plumbing disposed within one or moreinternal areas of said frame assembly and inserted through one or moreapertures of said metal studs.
 18. The structural wall of claim 17further comprising grommets disposed within the apertures of said metalstuds to avoid any inserted wiring or plumbing from directly contactingthe metal studs.
 19. The structural wall of claim 11 wherein saidconcrete mixture having a thickness applied over said lath of about twoinches.
 20. The structural wall of claim 11 wherein each metal stud issecured to the top track by two screws on the interior side of the frameassembly and two screws on the exterior side of the frame assembly andeach metal stud is secured to the bottom track by two screws on theinterior side of the frame assembly and two screws on the exterior sideof the frame assembly.
 21. The structural wall of claim 11 wherein saidmetal lath is a metal lath ⅜″ high rib lath having a herringbone meshpattern with ⅜″ V-shaped ribs running the length of said lath at 4½″intervals and 3/16″ intermediate ribs.
 22. The structural wall of claim11 wherein said interior member is a ⅝″ type gypsum board.
 23. Thestructural wall of claim 11 wherein said metal studs are constructedfrom galvanized steel.
 24. A structural wall for a building, comprising:a frame assembly having a substantially U-shaped top track, asubstantially U-shaped bottom track and a plurality of galvanized steelwall studs secured at a top end to the top track and at a bottom end tothe bottom track, each of said wall studs having a plurality of spacedapart apertures, said frame assembly having an exterior side and aninterior side, said frame assembly defining an internal area betweeneach adjacent pair of wall studs, said top track and said bottom track;a metal high rib lath secured to said metal wall studs on an exteriorside of said frame assembly; a concrete mixture applied over andcovering the metal high rib lath; a piece of ⅝″ type gypsum boardsecured to the metal studs by a plurality of screws on the interior sideof said frame assembly; a piece of R-19 or higher rated insulationinserted within each internal area of said frame assembly; and wiringand plumbing disposed within one or more internal areas of said frameassembly and inserted through one or more apertures of said wall studs.25. The structural wall of claim 24 wherein said bottom track of saidframe assembly is secured to concrete slab of a building by a pluralityof anchor bolts.
 26. The structural wall of claim 24 wherein each pieceof insulation having a moisture barrier backing paper.
 27. Thestructural wall of claim 24 further comprising a moisture barrierbacking paper secured to the metal high rib lath.
 28. The structuralwall of claim 24 further comprising grommets disposed within theapertures of said metal studs to avoid any inserted wiring or plumbingfrom directly contacting the metal studs.
 29. The structural wall ofclaim 24 wherein said concrete mixture having a thickness applied oversaid lath of about two inches.
 30. The structural wall of claim 24wherein each wall stud is secured to the top track by two screws on theinterior side of the frame assembly and two screws on the exterior sideof the frame assembly and each metal stud is secured to the bottom trackby two screws on the interior side of the frame assembly and two screwson the exterior side of the frame assembly.
 31. The structural wall ofclaim 24 wherein said metal lath is a metal lath ⅜″ high rib lath havinga herringbone mesh pattern with ⅜″ V-shaped ribs running the length ofsaid lath at 4½″ intervals and 3/16″ intermediate ribs.
 32. A method forconstructing a structural wall for a building comprising the steps of:(a) securing a plurality of metal wall studs to a bottom track and a toptrack to provide a frame assembly having an interior side, an exteriorside and a plurality of internal areas defined between adjacent wallstuds, the bottom track and the top track; (b) securing a high rib metallath to the plurality of metal wall studs at the exterior side of saidframe assembly; (c) applying a concrete mixture over said high rib metallath; (d) installing insulation within each internal area of said frameassembly; (e) installing any required wiring or plumbing within one ormore internal area of said frame assembly; and (f) and securing aninterior panel selected from a group consisting of sheet rock, drywallor gypsum board to said metal wall studs at the interior side of saidframe assembly.
 33. The method of claim 32 further comprising the stepof attaching moisture barrier backing paper to the insulation.
 34. Themethod of claim 32 further comprising the step of attaching moisturebarrier backing paper to the high rib metal lath.
 35. The method ofclaim 32 wherein said concrete mixture is applied over the high ribmetal lath in three coats to a thickness of about 2 inches.
 36. Themethod of claim 32 further comprising the step of securing the bottomtrack to a concrete slab of the building.
 37. A method for constructinga structural wall for a new building remote from the building site andnot exposed to outside elements during its construction, said methodcomprising the steps of: (a) while inside an existing structure and notexposed to outside weather conditions securing a plurality of metal wallstuds to a bottom track and a top track to provide a frame assemblyhaving an interior side, an exterior side and a plurality of internalareas defined between adjacent wall studs, the bottom track and the toptrack; (b) securing a high rib metal lath to the plurality of metal wallstuds at the exterior side of said frame assembly; (c) applying aconcrete mixture over said high rib metal lath; (d) installinginsulation within each internal area of said frame assembly; (e)installing any required wiring or plumbing within one or more internalarea of said frame assembly; (f) and securing an interior panel selectedfrom a group consisting of sheet rock, drywall or gypsum board to saidmetal wall studs at the interior side of said frame assembly; (g)transporting the frame assembly with secured metal lath having appliedconcrete mixture, secured interior panel and installed insulation,wiring and plumbing from the existing structure to a building site for anew building; and (h) securing the bottom track to a concrete slabpresent at the building site.
 38. The method of claim 37 furthercomprising the step of attaching moisture barrier backing paper to theinsulation prior to installing the insulation in the internal areas ofthe frame assembly.
 39. The method of claim 37 further comprising thestep of attaching moisture barrier backing paper to the high rib metallath prior to securing the metal lath to the metal studs of the frameassembly.
 40. The method of claim 37 wherein said concrete mixture isapplied over the high rib metal lath in three coats to a thickness ofabout 2 inches.